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Traditional Advanced Process Control (APC) stabilizes individual units using fixed models within a narrow operating window it does not search for better operating points across assets. Energy management systems provide monitoring, reporting, and alarms around energy KPIs, but they do not actively optimize or update procedures.

OptiStudio works as a layer above both. It learns from historical and live plant data, runs multi-objective optimization across assets and utilities, and feeds results directly into operator recommendations and updated SOP drafts. In practice: APC keeps your loops stable, your EMS tracks performance, and OptiStudio continuously finds better setpoints, modes, and procedures to reduce cost and CO₂ — while respecting the constraints both systems enforce.

OptiStudio does not replace your document management system — it connects to it. The platform ingests your existing SOPs from your current repository (DMS, SharePoint, ERP module, or file exports), parses them, and maps each parameter and step to the underlying process and optimization models.

It then compares live plant operation and optimized strategies against those documented steps, identifying gaps, obsolete instructions, and high-risk deviations. For each targeted unit or process, OptiStudio generates an updated SOP draft aligned with the optimization output. That draft is routed through your existing approval workflow — process engineering, HSE, operations before it becomes a controlled document. Versioning stays in your system. OptiStudio accelerates the analysis, drafting, and impact quantification without touching your governance structure.

At minimum, a typical engagement requires:

• Process time-series data from your DCS/SCADA or historian for the lines or utilities in scope setpoints, measurements, and status signals.
• Production, quality, and lab data throughput, product type, quality metrics, and key raw-material properties.
• Energy data at equipment or line level meters, fuel flows, and tariff information, with CO₂ data where available.
• Existing SOPs and work instructions for the targeted assets in any structured format — Word, PDF, or DMS exports

Data does not need to be perfect. A first phase typically includes data quality profiling and a lightweight SOP inventory to identify which processes are most optimization-ready and where the fastest value lies.

Yes. OptiStudio is designed to start focused and scale deliberately. The typical pattern is to begin with a single production line, kiln, furnace, or utility system where energy and CO₂ impact are high and data availability is strong prove value, refine workflows, and establish a repeatable playbook.

Once the first use case is operational, the same data models, optimization patterns, and SOP workflows replicate across additional lines, plants, or regions with plant-specific tuning where needed. Governance structures, user roles, and templates are managed at platform level, so each expansion builds on what already exists rather than starting from scratch.

OptiStudio is built for industrial environments where security and auditability are non-negotiable. The platform covers four areas:

• Network and deployment — segmented architectures, encryption in transit and at rest, hardened containers or VMs aligned with zero-trust principles, with cloud and on-premises deployment options.
• Identity and access — integration with corporate identity providers via SSO, role-based access control, and least-privilege permissions across data, models, and SOP documents.
• Data protection and auditability — detailed audit logs for data access, optimization runs, SOP changes, and user actions. Sensitive data can remain on-premises while selected components run in the cloud.
• Secure development — security scanning in the CI/CD pipeline, dependency monitoring, and runtime controls aligned with NIST AI RMF-style guidelines.